Power tool having an electronically commutated motor and double insulation

ABSTRACT

A power tool has a housing a housing having an electronically commutated motor disposed therein. The motor has a rotor and a stator. The rotor has permanent magnets. The stator has a lamination stack and windings wound therein. Features are provided to provide double insulation.

CROSS REFERENCE TO RELATED APPLICATION

This Application is a divisional of U.S. patent application Ser. No.12/114,211 filed on May 2, 2008. The entire disclosure of the aboveapplication is incorporated herein by reference.

FIELD

The present invention relates to power tools, and more particularly to apower tool having a brushless motor with double insulation.

BACKGROUND

A variety of different types of power tools have electric motors. By wayof example and not of limitation, these power tools include drills,hammer drills, saws, sanders, grinders, impact wrenches, and the like.

Orbital sanders, such as random orbital sanders, are used in a varietyof applications where it is desirable to obtain an extremely smoothsurface free of scratches and swirl marks. Such applications typicallyinvolve wood working applications such as furniture construction orvehicle body repair applications, just to name a few.

Random orbital sanders typically include a platen that is drivenrotationally by a motor-driven spindle. The platen is driven via afreely rotatable bearing that is eccentrically mounted on the end of thedrive spindle. Rotation of the drive spindle causes the platen to orbitabout the drive spindle while frictional forces within the bearing, aswell as varying frictional loads on the sanding disc attached to theplaten, cause the platen to also rotate about the eccentric bearing,thereby imparting the “random” orbital movement to the platen. Typicallysuch random orbit sanders also include a fan member which is driven bythe output shaft of the motor. The fan member is adapted to draw dustand debris generated by the sanding action up through openings formed inthe platen and into a filter or other like dust collecting receptacle.

One such prior art random orbital sander is disclosed in U.S. Pat. No.5,392,568 for Random Orbit Sander Having Braking Member (the entiredisclosure of which is incorporated herein by reference). For context, ashort section of the '568 patent describing a random orbital sander isrepeated here. With reference to FIG. 1, a random orbital sander 10generally includes a housing 12 which includes a two-piece upper housingsection 13 and a two-piece shroud 14 at a lower end thereof. Removablysecured to the shroud 14 is a dust canister 16 for collecting dust andother particulate matter generated by the sander during use. A platen 18having a piece of sandpaper 19 (FIG. 2) releasably adhered thereto isdisposed beneath the shroud 14. The platen 18 is adapted to be drivenrotationally and in a random orbital pattern by a motor disposed withinthe upper housing 13. The motor (shown in FIG. 2) is turned on and offby a suitable on/off switch 20 which can be controlled easily with afinger of one hand while grasping the upper end portion 22 of thesander. The upper end portion 22 further includes an opening 24 formedcircumferentially opposite that of the switch 20 through which a powercord 26 extends.

The shroud 14 is preferably rotatably coupled to the upper housingsection 13 so that the shroud 14, and hence the position of the dustcanister 16, can be adjusted for the convenience of the operator. Theshroud section 14 further includes a plurality of openings 28 (only oneof which is visible in FIG. 1) for allowing a cooling fan driven by themotor within the sander to expel air drawn into and along the interiorarea of the housing 12 to help cool the motor.

With reference now to FIG. 2, the motor can be seen and is designatedgenerally by reference numeral 30. The motor 30 includes an armature 32having an output shaft 34 associated therewith. The output shaft ordrive spindle 34 is coupled to a combined motor cooling and dustcollection fan 36. In particular, fan 36 comprises a disc-shaped memberhaving impeller blades formed on both its top and bottom surfaces. Theimpeller blades 36 a formed on the top surface serve as the cooling fanfor the motor, and the impeller blades 36 b formed on the bottom surfaceserve as the dust collection fan for the dust collection system.Openings 18 a formed in the platen 18 allow the fan 36 b to draw sandingdust up through aligned openings 19 a in the sandpaper 19 into the dustcanister 16 to thus help keep the work surface clear of sanding dust.The platen 18 is secured to a bearing retainer 40 via a plurality ofthreaded screws 38 (only one of which is visible in FIG. 8) which extendthrough openings 18 b in the platen 18. The bearing retainer 40 carriesa bearing 42 that is journalled to an eccentric arbor 36 c formed on thebottom of the fan member 36. The bearing assembly is secured to thearbor 36 c via a threaded screw 44 and a washer 46. It will be notedthat the bearing 42 is disposed eccentrically to the output shaft 34 ofthe motor, which thus imparts an orbital motion to the platen 18 as theplaten 18 is driven rotationally by the motor 30.

One disadvantage the electrically powered random orbital sanders havecompared to pneumatic sanders is due to the height of the sander.Heretofore, electrically powered random orbital sanders and orbitalsanders have used mechanically commutated motors, such as universalseries motors in the case of corded sanders, which dictates that theoverall height of the electrically powered sander is greater than acomparable pneumatic sander. In electrically powered random orbitalsanders, if the user grasps the sander by placing the palm of the user'shand over the top of the sander, the user's hand is sufficiently farfrom the work that the user is sanding to cause more fatigue than is thecase with pneumatic sanders where the user can grasp the sander close tothe work piece. This often leads to user's grasping electrically poweredrandom orbital sanders on the side of the sander. This tends to beawkward compared to grasping the top of the housing. Also, the greaterheight of the electrically powered random orbital sander causes morewobble compared to the lower height pneumatic random orbital sander. Theelectrically powered sander is heavier than a comparable pneumaticsander due to the weight of the motor, further contributing to thewobble problem. The user of the electrically powered random orbitalsander thus must grasp it more tightly than the lower height and weightpneumatic random orbital sander, causing additional fatigue in theuser's hand.

SUMMARY

A power tool has a housing having an electronically commutated motordisposed therein. The motor has a rotor and a stator. The rotor haspermanent magnets disposed around a periphery of the rotor and a shaft.The stator has a lamination stack and windings wound therein. In anaspect, a sense magnet tray is affixed to the shaft of the rotor inproximity to a sensor disposed in the housing. The sensor is axiallyspaced from the sense magnet tray. A sense magnet is affixed to thesense magnet tray. The sense magnet tray has a circumferential skirtthat extends around an outer edge of the sense magnet. The sense magnettray has circumferential skirt having a height at least equal to aheight of the sense magnet. A shortest uninsulated path between thesense magnet and a closest conductive part of the rotor is along aserpentine path that runs from the sense magnet, along an outer side ofthe sense magnet tray circumferential skirt and along a bottom of thesense magnet tray.

In an aspect, an upper bearing bridge extends across a top of thestator. The upper bearing bridge has a bearing pocket in which an upperbearing on the rotor shaft is received. The upper bearing bridgeincludes an annular skirt made of electrically insulative material thatextends from a periphery of the bearing pocket toward the sense magnettray. A shortest uninsulated path between any live component of acircuit board on which the sensor is mounted and the upper bearing isalong a serpentine path that extends from the circuit board along anouter surface of the annular skirt.

In an aspect, the rotor includes an electrically insulative sleevedisposed around the permanent magnets. The sleeve has opposed axial endsthat extend beyond respective opposed axial ends of the permanentmagnets. A shortest uninsulated path between the stator lamination stackand a closest conductive part of the rotor is around an axial end of theinsulative sleeve.

In an aspect, electrically insulative shields are disposed at radiallyinner sides of the stator windings that have opposed axial ends thatextend beyond respective opposed axial ends of the stator windings.

In an aspect, a lower bearing bridge includes a lower bearing retainermade of an electrically insulative material. The lower bearing retaineris affixed to the lower bearing bridge by at least one screw extendingthrough a screw hole in the lower bearing bridge wherein a head of thescrew is recessed in a screw pocket in the lower bearing bridge with atop surface of the screw head below a top surface of the upper bearingbridge. A shortest uninsulated path from the stator windings to thescrew head is along a serpentine path along an outer surface of one ofthe insulative shields, the top surface of the lower bearing retainerand into the screw pocket.

In an aspect, the rotor is overmolded with an overmold of material thatis electrically insulative. The overmold includes a sense magnet trayformed therein when the overmold material is molded. The overmoldmaterial surrounds the permanent magnets and affixes them in place.

In an aspect, a yoke of ferromagnetic material is disposed in the sensetray with the sense magnet disposed on top of the yoke. The sense magnetis made of ferrite.

In an aspect the sense magnet is a multi-pole ring magnet.

In an aspect, the sense magnets includes a plurality of magnets. In anaspect, a method of making a power tool includes placing a rotor with asense magnet thereon in a mold and injection molding magnet materialinto the sense magnet tray to form a sense magnet. In an aspect, moldingmagnetic material includes molding NdFeB material to form the sensemagnet in the sense magnet tray and a yoke of ferromagnetic material isnot provided in the sense magnet tray.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of a prior art random orbital sander;

FIG. 2 is a cross-sectional view of the sander of FIG. 2 taken along theline 2-2;

FIG. 3 is a perspective view of a prior art electrically powered randomorbital sander;

FIG. 4 is a perspective view, partially broken away, of the sander ofFIG. 1;

FIG. 5 is a cross-section view of the sander of FIG. 4 taken along theline 5-5;

FIG. 6 is a schematic of a control system for an electronicallycommutated motor of the sander of FIGS. 3-5;

FIG. 7 is a side cross-section of the sander of FIG. 3;

FIG. 8 is perspective view of a motor/bearing assembly having doubleinsulation in accordance with an aspect of the present disclosure;

FIG. 9 is a cross-section view of the motor/bearing assembly of FIG. 8taken along the line 9-9;

FIG. 10 is a cross-section view of the motor/bearing assembly of FIG. 8taken along the line 10-10;

FIG. 11 is a perspective cross-section of a sense magnet retainer;

FIG. 12 is a perspective view of a lower bearing retainer, lower bearingand rotor shaft of the motor/bearing assembly of FIG. 8;

FIG. 13 is a cross-section of a variation of the motor/bearing assemblyof FIG. 8;

FIG. 14 is a cross-section of an overmolded rotor in accordance with anaspect of the present disclosure;

FIG. 15 is a cross-section of a rotor having molded sense magnets moldedin accordance with an aspect of the present disclosure; and

FIG. 16 is a perspective view of a sense magnet tray of the rotor ofFIG. 15.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is in no wayintended to limit the invention, its application, or uses. It should beunderstood that throughout the drawings, corresponding referencenumerals indicate like or corresponding parts and features.

Referring to FIGS. 2-5, a low profile power tool 100 is shown. Lowprofile power tool 100 will be described in the context of a randomorbital sander and will be referred to as sander 100, but it should beunderstood that it can be other types of power tools where holding thepower tool near where it contacts the work piece would be advantageous,such as orbital sanders (which are sometimes known as “quarter sheet”sanders”).

Sander 100 includes a housing 102 and an orbit mechanism 104 disposedbeneath housing 102. A dust canister 106 may illustratively be removablysecured to housing 102. Orbit mechanism 104 and dust canister 106 mayillustratively be conventional orbit mechanisms and dust canisters thathave been used on prior art orbital sanders, such as disclosed in theabove referenced U.S. Pat. No. 5,392,568 (the entirety of which isincorporated herein by reference). Orbit mechanism 104 includes a pad orplaten 108 to which a piece of sandpaper 110 can be releasably adhered.

Orbit mechanism 104 is adapted to be driven rotationally and in a randomorbital pattern by a motor 112 disposed within housing 102. Motor 112 isturned on and off by a suitable on/off switch 114. Variable speed ofmotor 112 may illustratively be provided by a trigger switch 116,illustratively having a speed potentiometer 406 (FIG. 4). Trigger switch116 may illustratively be a paddle switch illustratively having a paddletype actuator member 117 shaped generally to conform to a palm of auser's hand. Trigger switch 116 may be referred to herein as paddleswitch 116. It should be understood, however, that paddle switch 116could also include on/off switch 114. In the embodiments shown in FIGS.2-5, sander 100 is illustratively a corded sander, that is, powered bybeing connected to AC mains, and a power cord 118 extends out through ahole 120 in housing 102.

A top 103 of housing 102 is shaped to provide an ergonomic palm grip 107for the user to grasp. Top 103 is shaped to have an arcuatecross-section that generally conforms with a palm of a user's hand, withedges 105 curving back to housing 102, which necks down beneath edges105. A user can thus grip sander 100 by holding the top 103 of sander100 in the palm of the user's hand and grasping edges 105 with theuser's fingers which can extend under edges 105. While palm grip 107 ofsander 100 is shown in FIGS. 2-5 as being generally round (when viewedfrom the top), it should be understood that palm grip 107 can have othershapes, such as oval, teardrop, elliptical, or the like. Palm grip 107allows the user to keep the user's hand more open when grasping sander100. The low profile of sander 100, discussed below, cooperates withpalm grip 107 to allow the user to grasp the sander 100 more lightlycompared to prior art corded random orbital and orbital sanders and thushelps prevent the user's fingers from cramping. Also, the height ofhousing 102 is sufficient to allow the user to grasp sander 100 from theside if so desired.

In an embodiment, sander 100 may include a mechanical braking member,such as brake member 48 and corresponding ring 61 (shown in phantom inFIG. 3) of the type described in U.S. Pat. No. 5,392,568.

Motor 112 is preferably an electronically commutated motor having arotor 200 (FIG. 2) with an output shaft 300 (FIG. 3) associatedtherewith to which orbit mechanism 104 is coupled in conventionalfashion, such as disclosed in U.S. Pat. No. 5,392,568. Motor 112 may bean electronically commutated motor of the type known as brushless DCmotors (which is somewhat of a misnomer as the electronic commutationgenerates AC waveforms, when viewed over a full turn of the motor, thatexcite the motor). Motor 112 may also be an electronically commutatedmotor of the type known as AC synchronous motors which are excited withsinusoidal waveforms.

As is known, motor power for an electronically commutated motor, for agiven electrical and magnetic load, is determined by D²L where D is thediameter of the motor and L is the height of the laminations of thestator. Motor 112 also has a stator 202 having a plurality of windings204 wound about lamination stack or stacks 302. (Lamination stack(s) 302are formed in conventional fashion and may be a single stack or aplurality of stacks.) Rotor 200 includes a plurality of magnets 304disposed around its periphery 206. Position sensors 308 (FIG. 7) aremounted in housing 102 about rotor 200. Position sensors 308 mayillustratively be Hall Effect sensors with three position sensors spaced120 degrees about rotor 200.

Motor 112 is a low profile or “pancake” style motor. That is, thediameter of motor 112 is large compared to the height of laminationstacks 302. The height of windings 204 are also kept low keeping theoverall height or length of motor 112 low. As used herein, a motor isconsidered “low profile” if it has a diameter to lamination stack heightratio of at least 2:1 and the diameter of the motor is greater than theheight or length of the motor. In an embodiment, motor 112 has adiameter to lamination height ratio of greater than five. Also, by usingan electronically commutated motor as motor 112, the weight of motor 112is significantly less for a given power compared to mechanicallycommutated motors, such as universal series motors. The rotor 200 ofelectronically commutated motor 112 having a rated power output of 200watts has a weight of about 30 grams. The armature of a universal seriesmotor having a rated power output of 120 watts has a weight of about 190grams. Assuming a weight of approximately 50 grams for the electronicsthat controls the electronically commutated motor, the electronicallycommutated motor still weighs significantly less than a universal motorhaving comparable power. Additionally, electronically commutated motorsare quieter than universal series motors due to the elimination of themechanical commutator. However it should be understood that motor 112 isnot limited to electronically commutated motors and can be any motorthat can be constructed with a low profile. In addition toelectronically commutated motors, switched reluctance motors, inductionmotors, brush DC motors, axial permanent magnet motors (brush andbrushless), and flux switching motors could be used for motor 112. Motor112 may illustratively have a rated power output of at least 40 watts.

As mentioned, the sander 100 may preferably be a random orbital sanderor orbital sander. Random orbital sanders and orbital sanders aretypically used to sand larger surfaces, with smaller sanders known as“detail” sanders which are used to sand smaller surfaces. As such,platen 108 when used in a random orbital sander would typically have adiameter of five or six inches. (Random orbital sanders having a fiveinch diameter platen and random orbital sanders having a six inchdiameter platen are the most commonly sold random orbital sanders.)Orbital sanders typically have a rectangular platen, with typical widthsof five or six inches. Motor 112 may illustratively have at least 70watts of power with a diameter to lamination height ratio of at least2:1 for a sander having a five inch platen, and preferably at least 120watts of power and a diameter to lamination height ratio of at least3:1. Motor 112 may illustratively have at least 100 watts of power witha diameter to lamination height ratio of at least 2:1 for a sanderhaving a six inch platen, and may illustratively have at least 120 wattsof power and a diameter to lamination height ratio of at least 3:1. Inan embodiment, motor 112 may illustratively have at least 200 watts ofpower with a diameter to lamination height ratio of at least 3:1.

Using a low profile motor, such as motor 112 described above, in sander100 allows sander 100 to have a “low profile.” As used herein, a cordedsander is “low profile” if it has a diameter of palm grip 107 to sander100 height ratio of at least 0.4:1, and preferably at least 0.6:1 orgreater, such as 1:1, where the maximum height of sander 100 does notexceed 120 mm for a corded sander.

With reference to FIG. 3, the diameter 310 of platen 108 of theillustrative low profile random orbital corded sander 100 is six inches(152.4 mm), the height 312 of sander 100 is 95 mm and the outsidediameter 316 of top 103 of sander 100 (and thus of palm grip 107) is 90mm. Magnets 304 are illustratively high powered rare earth magnets. Themotor 112 has a rated power output of up to 200 watts with a diameter317 of 75 mm and stack height (height of lamination stack 302) of 10 mm,giving motor 112 a diameter to lamination height ratio of 7.5:1. Motor112 has an overall height 318 of 23 mm (illustratively determined by theheight of windings 204). The diameter of palm grip 107 mayillustratively range from 30 to 90 mm, and more preferably, from 70 to90 mm, with the height of sander 100 not exceeding 120 mm as mentionedabove. In an embodiment, the height of sander 100 is a maximum of 90 mm,the diameter of palm grip 107 is a maximum of 90 mm, and motor 112 has arated power output of at least 120 watts. In a variation, the height ofsander 100 is a maximum of 100 mm.

It should be understood that magnets 304 may illustratively be ferritemagnets or low powered bonded Neodymium magnets, in which event, motor112 would have a lower rated power. Using ferrite magnets for magnets304 would result in a decrease in rated power for motor 112, having thesame dimensions, of about 50% and using low powered bonded Neodymiummagnets for magnets 304 would result in a decrease in rated power formotor 112 of about 25%.

In an embodiment, motor 112 would have an illustrative rated power of atleast 70 watts and a diameter to stack height ratio of 2:1. In anotherembodiment, motor 112 would have an illustrative rated power of at least150 watts and a diameter to stack height ratio of 5:1.

As mentioned, palm grip 107 can have shapes other than round shapes. Insuch cases, the diameter of the palm grip for the purposes of the palmgrip diameter to sander height ratio is the minor diameter of the palmgrip.

The low profile aspect of sander 100 as mentioned reduces wobblecompared to prior art corded sanders. Since weight is often added to thefan used in random orbital sanders and orbital sanders, such as fan 36(FIG. 2), to counteract wobble, the weight of the fan can be reduced.For example, the weight of fan 36 in the prior art random orbital sander10 having a five or six inch diameter platen 108 would illustratively bein the range of 100-200 grams. This weight could be reduced to about70-120 grams in low profile sander 100. However, the weight of lowprofile sander 100 would illustratively be kept high enough to prevent“bouncing” when low profile sander 100 is applied to the workpiece.Illustratively, the weight of sander 100 would be in the 800 grams to1400 grams range where sander 100 has a five or six inch diameter platen108. This is comparable to the weight of prior art random orbital andorbital sanders as it is desirable that sander 100 have sufficientweight that that the sander 100 itself applies the needed pressure tourge the sander against the workpiece when sanding as opposed to theuser applying pressure to sander 100. The user then need only guide thesander 100 on the workpiece, or need only apply light pressure to thesander 100. But by being able to reduce the weight of the fan in sander100, the weight eliminated from the fan can be more optimallydistributed in sander 100, or all or a portion of it eliminated fromsander 100. Also, even if the weight of the fan is kept the same, theweight can be distributed in the fan to optimize performance aspects ofsander 100 other than to counteract wobble, or at least to the degreeneeded in prior art sanders.

As mentioned, motor 112 may illustratively be an electronicallycommutated motor that is electronically commutated in conventionalfashion using known electronically commutated motor control systems.These control systems can be adapted to provide additionalfunctionality, as discussed with reference to FIG. 4.

FIG. 6 shows an electronic motor commutation control system 400 forcontrolling motor 112. Control system 400 includes switchingsemi-conductors Q1-Q6 having their control inputs coupled to outputs ofan electronic motor commutation controller (also known as a brushless DCmotor controller) 402. Control system 400 includes a power supply 404coupled to power cord 118 that provides DC power to controller 402 viarectifier 418. A filter or smoothing capacitor 416 smoothes the outputof rectifier 418. Switch 114 is coupled to an input of controller 402 asis speed potentiometer 406 of paddle switch 116. As mentioned above,switch 114 and paddle switch 116 may be separate switch devices orincluded in the same switch device.

A matrix consisting of motor speed and/or current information is used bycontroller 402 to determine the PWM duty cycle at which it switchesQ1-Q6, which in turn controls the speed of motor 112. The setting ofspeed potentiometer 406, which may illustratively be determined by howfar actuator member 117 of paddle switch 116 is depressed, dictates thespeed at which controller 402 regulates motor 112 during operation ofsander 100. Switch 114 may illustratively have an on/off control-levelsignal, such as may illustratively be provided by a micro-switch, whichcan be interfaced directly to controller 402. Also, a non-contact typeof switch can be used, such as logic switch/transistor/FET, opticalswitch, or a Hall Effect sensor-magnet combination. It should beunderstood that switch 114 could be a mains switch that switches poweron and off to sander 100, or at least to semiconductors Q1-Q6.

Illustratively, three position sensors 308 are used to provide positioninformation of rotor 200 to controller 402 which controller 402 uses todetermine the electronic commutation of motor 112. It should beunderstood, however, that two or one positions sensors 308 could beused, or a sensor-less control scheme used. Speed information mayillustratively be obtained from these position signals in conventionalfashion.

Sander 100 may illustratively include a sensor, such as a pressuresensor 408, that senses when sander 100 is removed from the work piece,such as by sensing a decrease in pressure on platen 108. A force sensorsuch as a strain gauge type of force sensor may alternatively oradditionally be used. Based on the signal from pressure sensor 408crossing a threshold value, controller 402 transitions from an “idlespeed” mode where it regulates the speed of motor 112 at an idle speedto a “sanding speed” mode where it regulates the speed of motor 112based on the position of speed potentiometer 406, and vice-versa. Thus,when sander 100 is applied to the work piece, controller 402 willtransition to the “sanding speed” mode and when sander 100 is removedfrom the work piece, controller 402 will transition to the “idle speed”mode.

Alternatively, speed information determined from one or more of positionsensors 308 and/or motor current determined from a current sensor 410can be used by controller 402 to determine when to transition betweenthe “idle speed” mode and the “sanding speed” mode. In an open loopcontrol, the speed of the motor drops with load and the motor currentincreases with load for a given PWM duty cycle. Applying the sander tothe work piece as it is running increases the load on the motor anddecreases the motor speed. By determining the motor 112 speed and/orcurrent at the idle speed PWM duty cycle, it can be determined whethersander 100 is being loaded or not. Based on the deviations of the motor112 speed and/or current from a range of typical values when the motor112 is running unloaded at idle speed, controller 402 can determine thatsander 100 has been applied to the work piece and thus transition fromthe “idle speed” mode to the “sanding speed” mode. Similarly, based onthe deviations of the motor 112 speed and/or current from a range oftypical values when the motor 112 is running loaded, controller 402 candetermine that sander 100 has been lifted from the work piece and thustransition from the “sanding speed” mode to the “idle speed” mode. Theforegoing is described in more detail in U.S. Pat. No. 7,318,768 for LowProfile Electric Sander issued Jan. 15, 2008, the entire disclosure ofwhich is incorporated herein by reference.

In order to achieve the low profile nature of sander 100, it isimportant not only that motor 112 have the appropriate aspect ratio asdiscussed above, but also to minimize the effect that other componentshave on the height of sander 100. In this regard, with reference to FIG.7, the windings 204 are wound to minimize the height of the end turns ofwindings 204. A position sense magnet 700 affixed to rotor 200 sensed bysensors 308 may illustratively be axial in orientation and made axiallythin. Sensors 308 are mounted on a side of a printed circuit board 702that faces position sense magnet 700 and the printed circuit board 702illustratively located within 2.5 mm of the surface of position sensemagnet 700. This permits sensor 308 when they are Hall Effect sensors tobe properly activated by position sense magnet 700. To the extentpossible, printed circuit board 702 is propagated with surface mountcomponents to minimize the height of printed circuit board 702. Filteror smoothing capacitor 416, which filters or smoothes the output ofrectifier 418, is mounted within housing 102 in an orientation so thatit does not increase the height above printed circuit board 702.

Printed circuit board 702 includes a central hole 706 sized to permit adrive end bearing 708 to be passed through it during assembly. Rotor 200may thus be sub-assembled by first placing drive end bearing 708 on itand rotor 200 then “dropped into” housing 102 in which printed circuitboard 702 has previously been placed during assembly of sander 100.

Housing 102 includes a bearing pocket 710 in which an opposite drive endbearing 712 is received. Printed circuit board 702 may illustratively bedisposed in housing 102 between opposite drive end bearing 712 andwindings 204. In this event, printed circuit board 702 is disposed wherethe commutator and brushes in a brush motor, such as a universal motor,are typically disposed.

Cord 118 is brought in through an end cap of housing 102 and the wiresin cord 118 connected to printed circuit board 702. Leads of windings204 are brought up and connected to printed circuit board 702.

“Double insulation” as that term is commonly understood means that adevice has basic and supplementary insulation, each of which issufficient to prevent electrical shock. The internal electricalcomponents are insulated by the double insulation from contact with anyconductive part with which a user can come in contact. In this regard,compliance with double insulation requirements requires minimum spacingsalong non-insulated paths between live components and components thatcan become live if insulation fails and a conductive part that can betouched by a user. An example of a component that could become live inthe event of an insulation failure is the lamination stack of stator 202which could become live should the insulation on stator windings 204fail. As used herein, “live” means that the component is electricallylive.

With reference to FIGS. 8-10, a motor/bearing assembly 1000 for a lowprofile power tool, such as low profile power tool 100, is shown. Again,the description is in the context of a low profile random orbitalsander. It should be understood that the low profile power tool can beother types of power tools as discussed above.

Motor/bearing assembly 1000 has an electronically commutated motor 1002and double insulation in accordance with an aspect of the presentdisclosure. Electronically commutated motor 1002 is similar toelectronically commutated motor 112 described above with reference toFIGS. 3-7.

A sense magnet assembly 1004 is affixed to rotor 200′ in proximity tosensors 308 and axially spaced therefrom. In an aspect, sense magnetassembly 1004 includes one or more sense magnets 1006, illustrativelymade of ferrite, a back yoke 1008 made of ferromagnetic material,illustratively steel, to boost the flux of the sense magnets 1006, and asense magnet tray 1010 that holds the sense magnets 1006 and back yoke1008. Sense magnet tray 1010 is illustratively an annular tray having ahole through which rotor shaft 1020 extends. Sense magnet tray 1010 ismade of an electrically insulative materially, such as being molded ofan electrically insulative plastic. Sense magnets 1006 mayillustratively comprise a multi-pole ring magnet. In which case, sensemagnet tray 1010 illustratively includes an annular receiving pocket1012 that opens toward sensors 308 in which the steel ring thatcomprises back yoke 1008 and the ring magnet that comprises sensemagnets are received, with back yoke 1008 received in a bottom of thereceiving pocket 1012. The use of steel back yoke 1008 makes it possibleto use lower cost ferrite sense magnets instead of a higher power sensemagnets, such as bonded NdFeB (Neo), which are more expensive thanferrite magnets.

Sense magnet tray 1010 includes a generally annular main body 1014having an upwardly (as oriented in FIG. 9) extending circumferentialskirt 1016 that is disposed along radially outer edges 1018 of the sensemagnets 1006 to insulate the sense magnets 1006 from stator 202.′ Inthis regard, skirt 1016 has a height equal to or greater than a heightof sense magnets 1006. Sense magnet tray 1010, being made ofelectrically insulative material, insulates sense magnets 1006 (whichmight become live should they contact sensors 308 or printed circuitboard 1042 on which sensors 308 are mounted) from magnets 304, shaft1020 and laminations 1022 of rotor 200.′ This arrangement providesserpentine path 1023 that is the shortest uninsulated path between sensemagnets 1006 and the closest electrically conductive part of rotor 200′,in this case magnets 304. That is, the shortest uninsulated path fromsense magnets 1006 to the closest conductive part of rotor 200′ is alongserpentine path 1023 that extends from sense magnets 1006, along anouter surface of annular skirt 1016, and along a bottom of sense magnettray 1010. This serpentine path 1023 provides at least 8 mm of distancealong the shortest uninsulated path, which is serpentine path 1023,between sense magnets 1006 and the closest conductive part of rotor200.′

To assemble sense magnet assembly 1004, sense magnet tray 1010 ispressed onto shaft 1020 of rotor 200. Back yoke 1008 is placed inannular receiving pocket 1012 and affixed in place, such as with glue.Sense magnets 1006 are placed in annular receiving pocket 1012 on top ofback yoke 1008 and affixed therein, such as with glue. To providesecondary retention of sense magnets 1006 and back yoke 1008 in sensemagnet tray 1010, an annular retainer 1024 is affixed to sense magnettray 1010. As best shown in FIG. 11 annular retainer 1024 has a radiallyoutward extending flange 1026 that extends over at least a portion ofsense magnets 1006. Annular retainer 1024 illustratively has snaps 1028that snap to sense magnet tray 1010 to hold annular retainer 1024 inplace. In a variation, a rim 1300 is ultrasonically welded on sensemagnet tray 1010 to provide the secondary retention instead of annularretainer 1024, as shown in FIG. 13.

To insulate magnets 304 and laminations 1022 of rotor 200′ fromsurrounding live components or components that could become live, suchas lamination stack 302 of stator 202,′ an insulative sleeve 1030 isplaced around magnets 304, with sleeve 1030 axially extending beyondaxial ends of magnets 304. Illustratively, sleeve 1030 illustrativelyextends at least 1.85 mm beyond axial ends of magnets 304. Sleeve 1030may illustratively be a glass-reinforced epoxy sleeve, such as a PolygonTube® available from the Polygon Company of Walkerton, Ind. Thisprovides serpentine paths 1064 & 1065 (FIG. 9) between lower and upperportions of the stator lamination stack 302 and the closest conductiveparts of rotor 200,′ illustratively permanent magnets 304. That is, theshortest uninsulated paths from lower and upper portions of statorlamination stack 302 and the closest conductive parts of rotor 200′ arealong serpentine paths 1064 & 1065 that extend around respective axialends of sleeve 1030. These serpentine paths 1064 & 1065 provide at least4 mm of distance along the shortest uninsulated path between statorlamination stack 302 and the closest conductive part of rotor 200.′

It should be understood that rotor 200′ could have internal permanentmagnets affixed in lamination stack 1022 instead of surface mountedpermanent magnets 304 affixed to a periphery of lamination stack 1022.In which case, insulative sleeve 1030 would be placed around an outerperiphery of lamination stack 1022 and the closest conductive parts ofthe rotor with respect to the upper and lower portions of statorlamination stack 302 would be lamination stack 1022 or rotor 200.′

Motor/bearing assembly 1000 further includes an upper bearing bridge1032 (as oriented in FIGS. 10-12) and a lower bearing bridge 1034between which motor 1002 is disposed. Upper bearing bridge 1032 includesa central annular bearing pocket 1036 in which an upper bearing 1038 onrotor shaft 1020 is received. Upper bearing 1038 is pressed on rotorshaft 1020 toward an upper end thereof, illustratively, at the upper endof rotor shaft 1020. An insulative boot 1040, which may illustrativelybe molded of silicon rubber, is disposed around upper bearing 1038. Aprinted circuit board 1042 on which sensors 308 are mounted is affixedto a bottom surface 1041 of upper bearing bridge 1032. Upper bearingbridge 1032 also includes an annular skirt 1039 that extends downwardly(as oriented in FIGS. 9 & 10 from an outer periphery of bearing pocket1036 toward sense magnet tray 1010 so that it extends at least 3.485 mmbelow a bottom of upper bearing 1038 when upper bearing 1038 is receivedin bearing pocket 1036. This arrangement provides a serpentine path 1043that is the shortest uninsulated path from any live part of printedcircuit board 1042 (or any component mounted thereon) to the outer raceof upper bearing 1038. That is, the shortest uninsulated path from anylive part of printed circuit board 1042 (or any component thereon) tothe closest conductive part of rotor 200′ is along serpentine path 1043that extends from printed circuit board 1042 (or the appropriatecomponent thereon) along an outer surface of annular skirt 1039. Thisserpentine path 1043 provides at least 8 mm of distance along theshortest uninsulated path, which is serpentine path 1043, between theouter race of upper bearing 1038 and any live trace of printed circuitboard 1042.

Lower bearing bridge 1034 includes a bearing retainer 1044 (FIG. 10) inwhich a lower bearing 1046 is received. Lower bearing 1046 isillustratively pressed on rotor shaft 1020 toward a lower end thereof.Bearing retainer 1044 is made of electrically insulative material, suchas being molded of electrically insulative plastic. Bearing retainer1044 is affixed to lower bearing bridge 1034 by screws 1048 (FIG. 12)that are received in screw pockets 1050 so that heads 1052 of screws1048 are at least 0.6 mm below a top surface 1054 of bearing retainer1044.

Stator 202′ includes electrical insulation 1056 (FIG. 9) disposed aroundsurfaces of stator lamination stack 302 adjacent to stator windings 204which includes insulative shields 1058 at radially inner edges of statorwindings 204. Insulative shields 1058 extend above and below top andbottom edges of stator windings 204 at least 0.5 mm. Electricalinsulation 1056 may illustratively be a component molded of anelectrically insulative plastic.

The insulative shields 1058 and the recessing of screw heads 1052 ofscrews 1048 in screw pockets 1050 of bearing retainer 1044 provide aserpentine path 1060 (FIG. 10) between the bottom of stator windings 204and screw heads 1052. That is, the shortest uninsulated path from astator winding 204 and a screw head 1052 is along serpentine path 1060that extends along an outer surface of an insulative shield from statorwinding 204 to a screw head 1052. This serpentine path 1060 provides atleast 6 mm of distance along the shortest uninsulated path betweenstator windings 204 and screws 1048.

Sleeve 1030 and insulative shields 1058 provide a serpentine path 1062between stator windings 204 and magnets 304 which are the closestconductive part of rotor 200,′ illustratively magnets 304, to statorwindings 204. That is, the shortest uninsulated path from a statorwinding 204 and the closest conductive part of rotor 200′ is alongserpentine path 1062 that extends along an outer surface of aninsulative shield 1058 from a stator winding to the closest conductivepart of rotor 200,′ illustratively magnets 304. This serpentine path1062 provides at least 6 mm of distance along the shortest uninsulatedpath between stator windings 204 and magnets 304.

The insulative shields 1058 and circumferential skirt 1016 of sensemagnet tray 1010 provide a serpentine path 1062 (FIG. 9) between statorwindings 204 and sense magnets 1006. That is, the shortest uninsulatedpath from stator windings 204 to sense magnets 1006 is along serpentinepath 1062 that extends along an outer surface of an insulative shieldand around an axial end of the circumferential skirt 1016 from a statorwinding 204 to a sense magnet 1006. This serpentine path 1062 providesat least 4 mm of distance along the shortest uninsulated path betweenstator windings 204 and sense magnets 1006.

With reference to FIG. 14, a variation 1400 of rotor 200′ ofmotor/bearing assembly 1000 is described. Rotor 1400 includes a stack oflaminations 1402 made of loose steel laminations is pressed on rotorshaft 1404. Magnets 304 are then placed on lamination stack 1402 forminga rotor sub-assembly. The rotor sub-assembly is then placed in a moldand overmolded with a material, which in an aspect is a thermoplastic ora thermoset, to form overmold 1410. A sense magnet tray 1412 is moldedwhen the overmold material is molded and includes molded features tolocate sense magnet back yoke 1008. The sense magnet back yoke 1008 isplaced in the sense magnet tray and affixed in place, such as with glue.Sense magnets 1006 are then placed on sense magnet back yoke 1008 andaffixed in place, such as described above. Upper bearing 1038 is pressedon rotor shaft 1304.

Overmolding rotor 1400 simplifies the assembly of rotor 1300 and reducesthe need for certain parts, such as the E-clip that typically provides alower shoulder on the rotor shaft. Lower shoulder 1414 is molded whenthe overmold material is molded to form overmold 1410 as are features1416, 1418 that provide locations for placement of balancing putty 1420.Using an electrically insulative thermoplastic or thermoset for thematerial of which overmold 1410 is formed facilitates making the motorin which rotor 1400 is used double insulated.

By overmolding rotor 1400, magnets 304 need not be glued to laminationstack 1402 as magnets 304 are retained by the overmold 1410. Thestructure of rotor 1400 is simple, robust and less susceptible tofailure due to high centrifugal forces.

With reference to FIG. 15, a variation 1500 of rotor 200′ ofmotor/bearing assembly 1000 is described. Rotor 1500 without the sensemagnets is placed in a mold. Sense magnets 1502 are molded and injectionbonded in sense magnet sense tray 1504. Illustratively, sense magnets1502 are molded of a bonded NdFeB type material with a resin filler,eliminating the need for a ferromagnetic back yoke, which is not used.Sense magnet tray 1504 illustratively is formed to include features 1506(FIG. 16) that axially retain sense magnets 1502. This processsimplifies assembly as it minimizes the handling of parts. The sensemagnet assembly includes few parts, illustratively two, sense magnettray 1504 and sense magnets 1502.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

1. A power tool, comprising: a housing having an electronically commutated motor disposed therein; the motor having a rotor and a stator, the rotor having permanent magnets, the stator having a lamination stack and windings wound therein; the rotor overmolded with an overmold of material that is electrically insulative, the overmold including a sense magnet tray formed therein when the overmold material is molded, the overmold material surrounding the permanent magnets and affixed them in place; and a sense magnet tray received in the sense magnet tray.
 2. The apparatus of claim 1 wherein the electrically insulative material is an electrically insulative thermoplastic.
 3. The apparatus of claim 1 wherein the electrically insulative material is an electrically insulative thermoset.
 4. The apparatus of claim 1 wherein the overmold includes features formed therein during molding that receive balancing material.
 5. The apparatus of claim 1 including a yoke of ferromagnetic material disposed in the sense tray, the sense magnet disposed on top of the yoke, the sense magnet made of ferrite. 